Modular plasma arc torch

ABSTRACT

A modular plasma arc torch is provided that comprises a torch head and a torch lead, and a quick disconnect that is operatively engaged between the torch head and the torch lead. Accordingly, the torch head and torch lead may be quickly assembled and disassembled through the use of the quick disconnect. Further, the modular plasma arc torch also comprises a gas control device disposed within the plasma arc torch, which is operatively engaged between the torch head and the torch lead through the use of the quick disconnect according to the present invention. In addition, the quick disconnect may be used to connect a wide range of torch components within a plasma arc torch, thereby providing a reconfigurable plasma arc torch. Moreover, the quick disconnect according to the present invention conducts both gas and electric power from a power supply to the torch head for operation of the plasma arc torch.

FIELD OF THE INVENTION

[0001] The present invention relates generally to plasma arc torches andmore particularly to devices and methods for assembling anddisassembling torch components such as a torch head and a torch leadwithin the plasma arc torch.

BACKGROUND OF THE INVENTION

[0002] Plasma arc torches, also known as electric arc torches, arecommonly used for cutting, marking, gouging, and welding metalworkpieces by directing a high energy plasma stream consisting ofionized gas particles toward the workpiece. A typical manual plasma arctorch generally includes a torch head comprising nonremovable components(e.g., anode, cathode), and removable components, commonly referred toas consumables, along with a torch handle that houses or covers at leasta portion of the torch head and other torch components. The torch handlealso houses at least a portion of a torch lead, which generally providesa conduit for the supply of both gas and electric power to the torchhead for operation of the plasma arc torch. Further, the torch handle ispreferably constructed of an insulating material and is designed toallow a user to conveniently handle and operate the plasma arc torch.

[0003] An upper portion of the torch head typically includes a torchbody or housing in which the nonremovable components such a cathode, aninsulating body, and an anode are positioned, whereas a lower portion ofthe torch head is typically configured to accommodate the removableconsumable components. Generally, consumable components have a muchshorter life than other components of a plasma arc torch and are thusreplaced on a more regular basis. The consumable components may include,by way of example, an electrode, a torch tip (or nozzle), a gasdistributor, and a shield cup. Further, the consumable components aretypically releasably attached or connected to the torch body and/or tothe nonremovable components within the torch body, thereby allowing theconsumable components to be easily replaced on a regular basis.

[0004] Additionally, the upper portion of the torch head is typicallyconnected to the torch lead within the handle of the plasma arc torch,wherein such a connection is typically fixed rather than releasable aswith the consumable components. Occasionally, the fixed connectionbetween the torch head and the torch lead must be broken if a new torchhead or a new torch lead is required. For example, if a torch lead isdamaged and requires replacement, the lead is replaced in its entiretyby removing a series of connections and fittings, such as electricalwires and compression fittings, and reattaching a new torch lead throughthe same set of connections and fittings. With plasma arc torches of theknown art, however, replacing the torch lead or the torch head isrelatively time-consuming and rather cumbersome.

[0005] Alternately, the entire torch lead and the torch head assemblymay be replaced rather than replacing the torch lead or torch headseparately. Although replacing the entire assembly is more timeefficient, the associated cost is much higher than replacing anindividual torch head or torch lead. Therefore, a tradeoff existsbetween replacing individual components at a lower cost but with moretime, and replacing an entire torch assembly at a higher cost but inless time.

[0006] Additionally, known plasma arc torches generally include specificcomponents that are designed for a specific set of performancerequirements such as a torch head, a trigger, and a torch lead, amongothers, which together comprise a torch assembly for the specific set ofperformance requirements. Such components are further secured within thetorch as previously described, which results in a plasma arc torch thatis not easily reconfigurable to meet a different set of performancerequirements. For example, if a different power supply were being used,either an entirely different plasma arc torch would be required, or adifferent torch components would have to be replaced within the torch,which is time consuming and cumbersome as previously described.

[0007] Accordingly, a need remains in the art for a device and methodthat allows for quick and efficient replacement of torch componentswithin a plasma arc torch, yet which is relatively low cost. A furtherneed exists for such a device and method that is also capable ofconducting both gas and electric power for operation of the plasma arctorch and which is also relatively compact so as to not interfere withoperation of the plasma arc torch. Yet a further need exists for areconfigurable plasma arc torch and associated methods of assembly anddisassembly.

SUMMARY OF THE INVENTION

[0008] In one preferred form, the present invention provides a modularplasma arc torch comprising a torch head, a torch lead, and a quickdisconnect operatively engaged between the torch head and the torch leadsuch that the torch head and torch lead may be quickly assembled anddisassembled. Generally, the quick disconnect comprises a pin fittingthat is engaged within a socket adapter such that both gas and electricpower for operation of the plasma arc torch are conducted through thequick disconnect. The pin fitting further comprises a plurality ofresilient fingers with contact flanges at a proximal end thereof, andthe socket adapter further comprises an insulative socket housing with aconductive socket fitting disposed therein. Accordingly, the contactflanges engage the socket fitting to provide electrical contact forsupply of the electric power, while the socket housing insulates thearea surrounding the quick disconnect during use and operation of theplasma arc torch.

[0009] As used herein, a plasma arc apparatus, whether operated manuallyor automated, shall be construed by those skilled in the art to be anapparatus that generates or uses plasma for cutting, welding, spraying,gouging, or marking operations, among others. Accordingly, the specificreference to plasma arc cutting torches or plasma arc torches hereinshould not be construed as limiting the scope of the present invention.Furthermore, the specific reference to providing gas to a plasma arctorch should not be construed as limiting the scope of the presentinvention, such that other fluids, e.g. liquids, may also be provided tothe plasma arc torch in accordance with the teachings of the presentinvention.

[0010] In another form, the present invention provides a modular plasmaarc torch comprising a torch head, a gas control device, and a torchlead. Similarly, a quick disconnect is operatively engaged between thetorch head and the gas control device and also between the gas controldevice and the torch lead. Accordingly, torch components within theplasma arc torch, e.g., torch head, gas control device, torch lead, maybe quickly assembled and disassembled.

[0011] In other forms of the present invention, a torch head, a torchlead, and a gas control device are provided that comprise a quickdisconnect member disposed within an end thereof, wherein the quickdisconnect members conduct gas and electric power for operation of aplasma arc torch while allowing the torch head, the torch lead, and thegas control device to be quickly assembled and disassembled from withinthe plasma arc torch.

[0012] In yet another form, a quick disconnect for operable engagementof components that conduct both gas and electric power, not necessarilyspecific to a plasma arc torch, is provided that comprises a pin fittingengaged within a socket adapter as previously set forth. Similarly, thepin fitting comprises a plurality of resilient fingers with contactflanges and the socket adapter comprises a conductive socket fittingdisposed within an insulative socket housing. Accordingly, the contactflanges engage the socket fitting to provide electrical contact forsupply of the electric power.

[0013] Further, a modular plasma arc torch is provided that comprises aplurality of torch components operatively connected through acorresponding plurality of quick disconnects. Moreover, alternate quickdisconnects other than the pin fitting and socket adapter are providedin other forms of the present invention. In yet another form, a modularplasma arc torch handle is provided, wherein two handle halves may bequickly assembled and disassembled, thereby contributing to the overallmodularity of the plasma arc torch.

[0014] Additionally, the present invention provides methods ofassembling and disassembling a plasma arc torch, wherein the quickdisconnect members as previously described are placed in and removedfrom engagement with corresponding quick disconnect members of torchcomponents disposed within the plasma arc torch. Thus, the plasma arctorch may be quickly assembled and disassembled for purposes such asreplacement or repair, or for production assembly and disassembly, amongothers.

[0015] Further areas of applicability of the present invention willbecome apparent from the detailed description provided hereinafter. Itshould be understood that the detailed description and specificexamples, while indicating the preferred embodiment of the invention,are intended for purposes of illustration only and are not intended tolimit the scope of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

[0016] The present invention will become more fully understood from thedetailed description and the accompanying drawings, wherein:

[0017]FIG. 1 is a perspective view of a manually operated plasma arcapparatus constructed in accordance with the principles of the presentinvention;

[0018]FIG. 2 is a side view of a torch head and a torch lead operativelyengaged through a quick disconnect within a plasma arc torch andconstructed in accordance with the principles of the present invention;

[0019]FIG. 3 is a cross-sectional view of a quick disconnect, takenthrough the plane of FIG. 2, operatively engaged between a torch headand a torch lead within a plasma arc torch and constructed in accordancewith the principles of the present invention;

[0020]FIG. 4 is a cross-sectional view of a quick disconnect inaccordance with the principles of the present invention;

[0021]FIG. 5A is a cross-sectional view of a pin fitting engaging asocket adapter for engagement of a quick disconnect in accordance withthe principles of the present invention;

[0022]FIG. 5B is a cross-sectional view of a pin fitting disengaging asocket adapter for disengagement of a quick disconnect in accordancewith the principles of the present invention;

[0023]FIG. 6 is a perspective view of a pin fitting of a quickdisconnect disposed within a torch head and constructed in accordancewith the principles of the present invention;

[0024]FIG. 7 is an exploded perspective view of a torch head and a torchlead positioned for engagement, illustrating a threaded connectiontherebetween, and constructed in accordance with the principles of thepresent invention;

[0025]FIG. 8 is a side view of a torch handle comprising positioningribs to secure torch components therein and constructed in accordancewith the principles of the present invention;

[0026]FIG. 9 is a cross-sectional view of a torch head, a gas controldevice, and a torch lead operatively connected through first and secondquick disconnects within a plasma arc torch and constructed inaccordance with the principles of the present invention;

[0027]FIG. 10 is a perspective view of a modular plasma arc torch with aplurality of torch components operatively connected with a correspondingplurality of quick disconnects;

[0028]FIG. 11 is a cross-sectional view of another embodiment of a quickdisconnect constructed in accordance with the principles of the presentinvention;

[0029]FIG. 12 is a cross-sectional view of yet another embodiment of aquick disconnect employing canted coil springs and constructed inaccordance with the principles of the present invention; and

[0030]FIG. 13 is a perspective view of a modular plasma arc torch handleconstructed in accordance with the principles of the present invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0031] The following description of the preferred embodiments is merelyexemplary in nature and is in no way intended to limit the invention,its application, or uses.

[0032] Referring to the drawings, a modular plasma arc torch accordingto the present invention is generally operable with a manually operatedplasma arc apparatus as indicated by reference numeral 10 in FIG. 1.Typically, the manually operated plasma arc apparatus 10 comprises aplasma arc torch 12 connected to a power supply 14 through a torch lead16, which may be available in a variety of lengths according to aspecific application. Further, the power supply 14 provides both gas andelectric power, which flow through the torch lead 16, for operation ofthe plasma arc torch 12. Additionally, electric power as used hereinshould be construed as comprising not only the main power or current forgeneration of a plasma arc, but also power for other electricalfunctions such as signal pins or a pilot return that control additionaltorch functions, among others used within plasma arc torches.

[0033] Referring now to FIG. 2, a modular plasma arc torch according toone embodiment of the present invention is illustrated and generallyindicated by reference numeral 20. As shown, the modular plasma arctorch 20 comprises a torch head 22, a torch lead 24, and a quickdisconnect 26 operatively engaged between the torch head 22 and thetorch lead 24. Accordingly, the torch head 22 is removably connected tothe torch lead 24 through the quick disconnect 26, which is described ingreater detail below, such that the torch head 22 and the torch lead 24may be quickly assembled and disassembled. As further shown, the torchcomponents, e.g., torch head 22 and torch lead 24, are disposed within atorch handle 28, one half of which is removed for clarity.

[0034] In operation, both gas and electric power are supplied to thetorch head 22 through activation of a trigger system 30. Generally, thetrigger system 30 causes a power switch 32 disposed within the torchhandle 28 to activate the supply of gas and electric power. Alternately,the trigger system 30 may activate the supply of gas with a gas controldevice (not shown) disposed within the torch handle 28, which is furtherdescribed below. Operation of the trigger system 30 is described ingreater detail in copending application titled “Plasma Arc Torch TriggerSystem,” filed Feb. 26, 2002, and commonly assigned with the presentapplication, the contents of which are incorporated herein by reference.

[0035] The power switch 32 is in electrical communication with the powersupply 14 (shown schematically), which generates and supplies gas andelectric power. Accordingly, both gas and electric power are deliveredfrom the power supply 14, through the torch lead 24, and to the torchhead 22 for generation of a plasma arc and a subsequent plasma streamthat is ejected from a torch tip 34. Therefore, the quick disconnect 26according to the present invention must be capable of conducting bothgas and electric power for operation of the modular plasma arc torch 20.Furthermore, as used herein, the terms proximal or proximal directionshould be construed as meaning towards or in the direction of the powersupply 14, and the terms distal or distal direction should be construedas meaning towards or in the direction of the tip 34 of the plasma arctorch 12.

[0036] With reference to FIG. 3, the quick disconnect 26 according toone form of the present invention is shown operatively engaged betweenthe torch head 22 and the torch lead 24. As shown, the quick disconnect26 comprises a conductive pin fitting 40 engaged within a socket adapter42, the operation of which is described in greater detail below.Further, the socket adapter 42 comprises a conductive socket fitting 44,which is engaged by the pin fitting 40, and which is disposed with aninsulative socket housing 46. Additionally, individual wires 41, whichare preferably used for main cutting current power, are crimped overgrooves 43 defined on the socket fitting 44 with a collar 45 to provideelectrical continuity between the wires 41 and the socket fitting 44.Moreover, an insulative sheath 47 is crimped over the wires 41 with aring 49 to encase and protect the wires 41 from the surroundingenvironment.

[0037] As further shown, the torch head 22 comprises an insulativehousing 50, in which an anode 51 (positive side of the power supply), aninsulator body 52, and a cathode 53 (negative side of the power supply)are disposed. In operation, the insulator body 52 insulates the anode 51from the cathode 53, in addition to performing other gas distributionfunctions which are described in copending application titled “ContactStart Plasma Arc Torch,” filed Feb. 26, 2002, and commonly assigned withthe present application, the contents of which are incorporated hereinby reference.

[0038] Preferably, the pin fitting 40 is molded within the housing 50,although other methods of connecting the pin fitting 40 to the housing50 such as a threaded connection may also be employed. Additionally, theanode 51, the insulator body 52, and the cathode 53 are similarly moldedwithin the housing 50 in the preferred form of the present invention,although other connection methods such as a threaded connection may alsobe employed. In one form of the present invention, the anode 51, theinsulator body 52, and the cathode 53 as an assembly are operativelyconnected to the housing 50 using a quick disconnect in accordance withthe principles of the present invention, which is described in greaterdetail below.

[0039] Further details of the quick disconnect 26 are shown in FIG. 4,wherein the pin fitting 40 comprises a plurality of resilient fingers 54and a plurality of corresponding contact flanges 56 disposed at aproximal end of the resilient fingers 54. As shown, the contact flanges56 define a dual taper with first tapered surfaces 57 and second taperedsurfaces 58, which facilitate engagement and disengagement,respectively, of the quick disconnect 26 as described in further detailbelow. Preferably, the socket fitting 44 is secured within the sockethousing 46 using a snap ring 59 as shown, although other connectionmethods may be employed, including the connection as shown and describedin copending application “Tamperproof Pin Connection,” filed Nov. 9,2001, U.S. Ser. No. 10/014,384, which is commonly assigned with thepresent application and the contents of which are incorporated herein byreference. Accordingly, the socket housing 46 would comprise lockingfingers that would engage a collar defined on the socket fitting 44 suchthat the connection between the socket fitting 44 and the socket housing46 would be tamperproof.

[0040] As further shown, the socket housing 46 defines a taperedinternal shoulder 60 that facilitates insertion of the pin fitting 40,and more specifically the resilient fingers 54, into the socket fitting44. Additionally, the socket fitting 44 further comprises a sleeve 61disposed therein, defining a tapered surface 62 that facilitates removalof the pin fitting 40. Moreover, the sleeve 61 also limits the contactarea between the contact flanges 56 and the socket fitting 44 for properoperation of the quick disconnect 26. Further, the socket housing 46also defines radial bores 63 that extend from an exterior of the sockethousing 46 to a position adjacent the tapered internal shoulder 60. Theradial bores 63 are designed to prevent torch malfunction should a rigidobject other than the pin fitting 40 with resilient fingers 54 beinadvertently forced into the socket adapter 42, wherein if such anobject were forced into the socket housing 46, the radial bores 63 wouldcause the socket housing 46 to fracture proximate the location of theradial bores 63, thereby causing gas to leak from the socket adapter 42and reducing the risk of an inappropriate use of the quick disconnect 26and any possible torch malfunctions that may result.

[0041] Engagement and disengagement of the quick disconnect 26 inaccordance with the present invention is illustrated in greater detailin FIGS. 5A (engagement) and 5B (disengagement). As shown in FIG. 5A, asthe pin fitting 40 is inserted into the socket housing 46 along thedirection of arrow A, first tapered surfaces 57 of the contact flanges56 abut the tapered internal shoulder 60 defined within the sockethousing 46. As the pin fitting 40 is further inserted into the sockethousing 46, the tapered internal shoulder 60 causes the resilientfingers 54 to deflect radially inward as shown allowing the pin fitting40 to be further inserted into the socket housing 42, through the sleeve61, and into the socket fitting 44. When the contact flanges 56 of thepin fitting 40 pass through the sleeve 61, the resilient fingers 54deflect back radially outward such that the contact flanges 56 engage adistal internal bore 64 defined within the socket fitting 44.Accordingly, electrical contact is made between the pin fitting 40 andthe socket fitting 44.

[0042] To further maintain proper contact and to enable engagement anddisengagement, an outer diameter of the pin fitting 40 in the area ofthe contact flanges 56 is larger than an internal diameter of the distalinternal bore 64 within the socket fitting 44 such that an engagementforce is maintained between the pin fitting 40 and the socket fitting 44when the contact flanges 56 are disposed within the distal internal bore64. Additionally, the minimum diameter of the tapered internal shoulder60, proximate the sleeve 61, is smaller than the outer diameter of thepin fitting 40 in the area of the contact flanges 56 in an undeflectedstate so that the resilient fingers 54 may be deflected a sufficientamount for insertion into the socket fitting 44.

[0043] Referring now to FIG. 5B, the quick disconnect 26 is illustratedduring disengagement. As shown, when the pin fitting 40 is removed fromthe socket adapter 42 along the direction of arrow B, the second taperedsurfaces 58 of the resilient fingers 54 engage the tapered surface 62 ofthe sleeve 61, which causes the resilient fingers 54 to deflect radiallyinward and the pin fitting 40 may be further removed along the directionof arrow B. After the contact flanges 56 clear the tapered internalshoulder 60, the resilient fingers 54 deflect back radially outward andthe pin fitting 40 is disengaged from the socket adapter 42. As aresult, the quick disconnect 26 provides a relatively compact andefficient connection between torch components such as the torch head 22and the torch lead 24, and is further capable of conducting both gas andelectric power for operation of the plasma arc torch 12.

[0044] For conducting gas flow, the pin fitting 40 defines an internalbore 65 that is in fluid communication with the distal internal bore 64of the socket fitting 44, and also with a proximal internal bore 66defined by the socket fitting 44, each of which are sized according tospecific gas flow requirements. In operation, the gas flows from thepower supply 14 (not shown) through the proximal internal bore 66 of thesocket fitting 44, through the distal internal bore 64 of the socketfitting 44, and then through the pin fitting internal bore 65 forsubsequent delivery to the torch head 22 (not shown). Accordingly,interfaces between the pin fitting 40 and the socket housing 46, andalso between the socket fitting 44 and the socket housing 46, arepreferably sealed to inhibit the gas from leaking from the quickdisconnect 26. In one form of the present invention, first and secondo-rings, 68 and 70 respectively, are disposed at the interfaces suchthat the first o-ring 68 provides a gas-tight seal between the pinfitting 40 and the socket housing 46, and the second o-ring 70 providesa gas-tight seal between the socket fitting 44 and the socket housing46. Further, the socket housing 46 comprises an o-ring groove 72 tohouse the first o-ring 68, and similarly, the socket fitting 44comprises an o-ring groove 74 to house the o-ring 70, although theo-ring grooves may be disposed in either of the members between which asealed interface is desired.

[0045] For conducting electric power, the pin fitting 40 is in physicalcontact with the socket fitting 44 as shown, thus the pin fitting 40 andthe socket fitting 44 are conductive elements. More specifically, thecontact flanges 56 are in physical contact with the distal internal bore64 of the socket fitting 44 to provide the requisite electrical contactfor supply of the electric power from the power supply 14 (not shown) tothe torch head 22 (not shown). As further shown, the contact flanges 56preferably form a rounded profile between the first tapered surfaces 57and the second tapered surfaces 58 in order to maintain electricalcontact should either or both the pin fitting 40 and the socket adapter42 become misaligned. Additionally, the socket housing 46 is aninsulative element such that the area surrounding the quick disconnect26 is insulated during use and operation. Preferably, the pin fitting 40and the socket fitting 44 are a heat treated beryllium copper, and thesocket housing 46 is a plastic composition such as Nylon or Delrin®.

[0046] As further shown, the quick disconnect 26 also comprises a plug80 disposed on a shoulder 81 formed within the socket fitting 44,between the distal internal bore 62 and the proximal internal bore 66.The plug 80 is comprised of a nonconductive material such that if anobject other than the pin fitting 40 with resilient fingers 54 wereinadvertently inserted into the socket adapter 42, the plug 80 wouldinhibit electrical contact between the object and the socket fitting 44.Accordingly, the plug 80 reduces the risk of torch malfunction should anobject other than the pin fitting 40 with the resilient fingers 54 beinserted into the socket adapter 42.

[0047] Referring to FIG. 6, the pin fitting 40 is preferably cylindricalin shape, although other shapes may be employed in accordance with theteachings of the present invention. Preferably, a total of four (4)resilient fingers 54 are employed in the embodiment as illustratedherein, although a different number of resilient fingers 54 may be usedaccording to specific application requirements without departing fromthe scope of the present invention. Additionally, the pin fitting 40 isillustrated as being disposed within a proximal end 82 of the torch head22, however, the pin fitting 40 may alternately be disposed within thetorch lead 24 (not shown) while the socket adapter 42 (not shown) isdisposed within the torch head 22. Therefore, either side of the quickdisconnect 26, i.e. plug fitting 40 and socket adapter 42, may bedisposed within distal and proximal ends, respectively, of adjoiningtorch components and remain within the scope of the present invention.In addition to the proximal end 82, the torch head 22 may also comprisea quick disconnect member, i.e. the pin fitting 40 or the socket adapter42, at a distal end 83 for quickly connecting and disconnecting ananode, insulator body, and cathode assembly (not shown), which isdescribed in greater detail below.

[0048] Referring now to FIG. 7, the connection between the torch head 22and the torch lead 24 may be further secured through a secondaryconnection, namely, a threaded connection between the torch head 22 andthe torch lead 24. The threaded connection is achieved through athreaded extension 84 defined by the socket housing 46 that engages athreaded member 86 disposed within the proximal end 82 of the torch head22. As shown, the threaded extension 84 defines external threads 85 andextends from the socket housing 46, while the threaded member 86 definesinternal threads 87 and is disposed at the proximal end 82 of the torchhead 22 proximate the pin fitting 40. After the pin fitting 40 isengaged within the socket adapter 42, the quick disconnect 26 is furthersecured by threadably engaging the external threads 85 of the threadedextension 84 with the internal threads 87 of the threaded member 86. Thethreaded connection also provides an additional amount of coaxialtranslation of the pin fitting 40 relative to the socket adapter 42 soas to further engage and secure the quick disconnect 26. Preferably, thesocket housing 46 is rotatably mounted to the socket fitting 44 suchthat the threaded connection may be engaged without rotating the entiretorch lead 24, which could result in an undesirable twisting of thetorch lead 24. Accordingly, the snap ring 59 (not shown) as previouslydescribed provides the rotatable mounting such that the socket housing46 may be rotated independently without turning the entire torch lead 24and the socket adapter 42.

[0049] In another form, the threaded connection may further comprisethread protrusions and thread engagement members and as shown anddescribed in copending application titled “Dual Pitch LockingConnector,” filed Nov. 9, 2001, and commonly assigned with the presentapplication, the contents of which are incorporated herein by referencein their entirety. Generally, the threaded member 86 comprises twodiametrically opposed radial protrusions (not shown) that engage theexternal threads 85 of the threaded extension 84. Further, the externalthreads 85 comprise at least one thread protrusion (not shown) such thatat least one radial protrusion engages the thread protrusion to providean audible and tactile indication of a fully mated condition of thequick disconnect 26.

[0050] As shown in FIG. 8, the connection between the torch head 22 (notshown for clarity) and the torch lead 24 (not shown for clarity) mayalternately be further secured through the use of positioning ribs 89within the torch handle 28, rather than the threaded connection aspreviously described. After the pin fitting 40 is engaged within thesocket adapter 42 as previously described, the torch head 22 and thetorch lead 24 are placed within a half of the torch handle 28 betweenpositioning ribs 89 a and 89 b, which prevent movement of either thetorch head 22 or the torch lead 24 in a direction away from the quickdisconnect 26. Accordingly, the positioning ribs 89 a and 89 b furthersecure the connection between the pin fitting 40 and the socket adapter42. Furthermore, the positioning ribs 89 a and 89 b may be disposed ineither or both halves of the torch handle 28 and are preferablyintegrally formed within the torch handle 28, although the positioningribs 89 a and 89 b may alternately be separately attached within thetorch handle 28 without departing from the scope of the presentinvention.

[0051] The quick disconnect 26 according to the present invention mayalso be employed to provide a connection between additional torchcomponents within a plasma arc torch 12 rather than or in addition tobetween a torch head 22 and a torch lead 24 as previously described. Forexample, other torch components that may be quickly assembled anddisassembled using the quick disconnect 26 according to the presentinvention may comprise gas flow control components such as valves andorifices, electrical components such as voltage circuits, logic boards,and/or switches, torch head components such as an anode, a cathode, andan insulator, electrical adapters, and torch handles, among others.Accordingly, each component of a plasma arc torch may be easily andrapidly connected and disconnected according to the principles of thepresent invention, thereby providing a modular plasma arc torch that hasnot heretofore been observed in plasma arc torches.

[0052] As shown in FIG. 9, the quick disconnect 26 is further employedbetween the torch head 22 and a gas control device 90, (shown as a firstquick disconnect 26 a), and also between the gas control device 90 andthe torch lead 24, (shown as a second quick disconnect 26 b) in anotherform of the present invention. Generally, the gas control device 90 isemployed to provide control of the gas supply local to the torch handle28 of the plasma arc torch 12 and is activated by the trigger system 30.Additionally, gas control local to the torch handle 28 is disclosed incopending application titled “Torch Handle Gas Control” filed on Feb.26, 2002, and commonly assigned with the present application, thecontents of which are incorporated by reference.

[0053] As shown, the gas control device 90 comprises a distal end 92 anda proximal end 94, in which quick disconnect members as previously shownand described are disposed. For example, a socket adapter 42 a aspreviously described may be disposed within the distal end 92 of the gascontrol device 90 as shown, such that a pin fitting 40 a disposed withinthe proximal end 82 of the torch head 22 is engaged within the socketadapter 42 a. Alternately, the socket adapter 42 a may be disposed atthe proximal end 82 of the torch head 22, while the pin fitting 40 a isdisposed within the distal end 92 of the gas control device 90. Asfurther shown, a pin fitting 40 b is disposed within the proximal end 94of the gas control device 90, which is engaged within a socket adapter42 b disposed within the distal end 93 of the torch lead 24.Alternately, the socket adapter 42 b may be disposed within the proximalend 94 of the gas control device 90, while the pin fitting 40 b isdisposed within the distal end 93 of the torch lead 24.

[0054] Accordingly, the torch head 22 is removably connected to the gascontrol device 90 through the first quick disconnect 26 a, and the gascontrol device 90 is removably connected to the torch lead 24 throughthe second quick disconnect 26 b such that the torch head 22, the gascontrol device 90, and the torch lead 24 may be quickly assembled anddisassembled, thereby forming a modular plasma arc torch. Further, boththe gas and electric power are conducted through the first quickdisconnect 26 a and the second quick disconnect 26 b for operation ofthe plasma arc torch 12. Although the present invention is directed touse of the quick disconnect 26 for a connection between the torch head22, the gas control device 90, and/or the torch lead 24, the quickdisconnect 26 may also be employed with other torch components disposedwithin the plasma arc torch 12 in accordance with the teachings of thepresent invention.

[0055] For example, FIG. 10 illustrates a plasma arc torch 12 with aplurality of torch components having a quick disconnect 99 operativelyengaged between each of the torch components. As shown, the quickdisconnect 99 may be employed between a torch head 100 and an adapter102 within a torch handle 104. As a result, the torch handle 104 doesnot necessarily require disassembly for replacement of the torch head100. Further, the quick disconnect 99 may be employed between a cathode,insulator, anode assembly 106 and the torch head 100, between a torchlead 108 and the adapter 102, between a gas flow control component 110and the torch lead 108, between an electrical component 112 and thetorch lead 108, between a proximal end 114 of the torch lead 108 and anadapter 116 for connection to a particular power supply, and between aplurality of signal and power pins 118 and a conductive member 119,among a multitude of other possible combinations of torch componentswhich are too numerous to detail herein. Therefore, it should beunderstood by those skilled in the art that any number of torchcomponents may incorporate a quick disconnect to provide a modularplasma arc torch that is within the scope of the present invention andthe use of specific examples herein should not be construed as limitingthe scope of the present invention.

[0056] In addition to the quick disconnect 26 as shown and describedwith the pin fitting 40 and a socket adapter 42, other quick disconnectsmay also be employed between various torch components as describedherein in order to achieve a modular plasma arc torch without departingfrom the scope of the present invention. For proper operation of theplasma arc torch, however, the quick disconnect that is employed must becapable of conducting both electric power and gas through the quickdisconnect and between torch components. For example, the quickdisconnect may comprise a dual pitch locking connector as shown anddescribed in copending application titled “Dual Pitch LockingConnector,” filed Nov. 9, 2001, U.S. Ser. No. 10/035534, which iscommonly assigned with the present application and the contents of whichare incorporated herein by reference. Alternately, the quick disconnectmay comprise a pin and socket configuration wherein resilient fingersare disposed on a socket side of the quick disconnect rather than a pinside, such as on the main power socket as shown and described incopending application titled “Plasma Arc Torch Quick Disconnect,” filedNov. 9, 2001, which is commonly assigned with the present applicationand the contents of which are incorporated herein by reference.

[0057] Referring to FIG. 11, the quick disconnect may alternatelycomprise pin and socket members, 120 and 122 respectively, that areengaged and secured by a locking ring 124. As shown, a conductive pin126 defining a central bore 128 is engaged within a conductive socket130, which similarly defines a central bore 132. In operation, a workinggas is conducted through the central bores 128 and 132, and electricpower is conducted through the conductive pin 126 and the conductivesocket 130. Accordingly, an o-ring 133 or other sealing member commonlyknown in the art is preferably disposed within the quick disconnect asshown to seal the supply of gas. Further, the locking ring 124 secures apin housing 134 to a socket housing 136 through a threaded connection138, or through other connection methods commonly known in the art suchas a snap-lock or a pin and groove, among others. Accordingly, torchcomponents may be quickly assembled and disassembled through the use ofpin and socket members, 120 and 122, in addition to the locking ring124.

[0058] As shown in FIG. 12, the quick disconnect may alternatelycomprise at least one canted coil spring 140 disposed within a socket142 that engages and secures a pin 144 that is slidably disposed withinthe socket 142. In operation, the pin 144 is inserted into the socket142 and compresses the canted coil spring 140 upon engagement such thatthe canted coil spring 140 applies a radially inward force to secure thepin 144 within the socket 142. Preferably, the canted coil spring 140 isalso conductive so as to minimize any loss of electrical continuityacross the interface between the pin 144 and the canted coil spring 140.Additionally, a threaded connection may also be employed as previouslydescribed to further secure the connection between the pin 144 and thesocket 142.

[0059] Referring now to FIG. 13, yet another form of the modular plasmaarc torch is facilitated through the use of a modular torch handle 150.Rather than individual fasteners to secure first and second torch halves150 a and 150 b, respectively, the torch halves 150 a and 150 b defineflexible tabs 152 and receptacles 154, respectively, in one form of thepresent invention. As shown, the flexible tabs 152 are disposed along anupper periphery 156 of torch half 150 a and are preferably integrallymolded with the torch half 150 a. The corresponding set of receptacles154 are disposed along an upper periphery 158 of the torch half 150 band are also preferably integrally molded with the torch half 150 b.Additionally, the torch half 150 a defines positioning pins 160 along alower periphery 162, and the torch half 150 b defines correspondingpositioning holes 164 along a lower periphery 166. Similarly, thepositioning pins 160 and the positioning holes 164 are preferablyintegrally molded with the torch halves 150 a and 150 b, respectively.

[0060] To quickly assemble the torch halves 150 a and 150 b, therefore,the positioning pins 160 are placed within the positioning holes 164along the lower peripheries 162 and 166, and the upper peripheries 156and 158 are brought together such that the flexible tabs 152 may beengaged with the receptacles 154. Accordingly, the flexible tabs 152 aredepressed while the upper peripheries 156 and 158 are further broughttogether to engage the receptacles 154 as shown. It should be understoodby those skilled in the art that one or a plurality of flexible tabs 152and corresponding receptacles 154 may be employed without departing fromthe scope of the present invention. Additionally, the relative positionof the flexible tabs 152 and the receptacles 154, in addition to thepositioning pins 160 and the positioning holes 164, along theperipheries may be altered while remaining within the scope of thepresent invention.

[0061] In yet another form of the present invention, a method ofassembling the a plasma arc torch with the torch head 22 and torch lead24 is provided. The method comprises the step of placing a quickdisconnect member, (i.e., plug fitting 40 or socket adapter 42), that isdisposed within a distal end of the torch lead 24 in engagement with acorresponding quick disconnect member, (i.e., socket adapter 42 or plugfitting 40, respectively), that is disposed within the proximal end 82of the torch head 22. Accordingly, the torch head 22 and the torch lead24 are quickly assembled. Further, the method may comprise the step ofengaging a threaded member disposed on one of the quick disconnectmembers with a threaded extension on the corresponding quick disconnectmember, such that the torch head 22 is further secured to the torch lead24.

[0062] In another form, the present invention provides a method ofassembling a plasma arc torch with the torch head 22, the quickdisconnect 90, and the torch lead 24 components. The method comprisesthe steps of placing a quick disconnect member disposed within a distalend of the torch lead 24 in engagement with a corresponding quickdisconnect member disposed within the proximal end 94 of the gas controldevice 90, and placing a quick disconnect member disposed within thedistal end 92 of the gas control device 90 in engagement with acorresponding quick disconnect member disposed within the proximal end82 of the torch head 22, such that the torch head 22, the torch lead 24,and the gas control device 90 are quickly assembled. Additionally, themethod may comprise the step of engaging threaded members disposed onone set of quick disconnect members with threaded extensions on thecorresponding quick disconnect members, such that the torch head 22 isfurther secured to the gas control device 90, and the gas control device90 is further secured to the torch lead 24.

[0063] In yet another form of the present invention, a method ofdisassembling a plasma arc torch with the torch head 22 and the torchlead 24 disposed therein is provided. The method comprises the step ofdisengaging a quick disconnect member disposed within a distal end ofthe torch lead 24 from engagement with a corresponding quick disconnectmember disposed within the proximal end 82 of the torch head 22, suchthat the torch head 22 and the torch lead 24 are quickly disassembled.Similarly, the method may further comprise the step of disengaging athreaded member disposed on one of the quick disconnect members with athreaded extension on the corresponding quick disconnect member prior todisengaging the quick disconnect member disposed within the distal end93 of the torch lead 24 from engagement with the corresponding quickdisconnect member disposed within the proximal end 82 of the torch head22, such that the torch head 22 is unsecured from the torch lead 24.

[0064] Furthermore, a method of disassembling a plasma arc torch withthe torch head 22, the gas control device 90, and the torch lead 24disposed therein is provided. The method comprises the steps ofdisengaging a quick disconnect member disposed within a distal end ofthe torch lead 24 from engagement with a corresponding quick disconnectmember disposed within the proximal end 94 of the gas control device 90and disengaging a quick disconnect member disposed within the distal end92 of the gas control device 90 from engagement with a correspondingquick disconnect member disposed within the proximal end 82 of the torchhead 22, such that the torch head 22, the torch lead 24, and the gascontrol device 90 are quickly disassembled. Additionally, the method maycomprise the step of disengaging threaded members disposed on the quickdisconnect members from threaded extensions on the corresponding quickdisconnect members, such that the torch head 22 is unsecured from thegas control device 90 and the gas control device 90 is unsecured fromthe torch lead 24 prior to disengaging the quick disconnect members.

[0065] Accordingly, the modular plasma arc torch 20 according to theteachings of the present invention provides devices and methods thatallow for quick and efficient assembly and disassembly of a wide varietyof torch components within a plasma arc torch. Torch components may beeasily removed and replaced if damaged, and furthermore, areconfigurable torch is provided wherein different design functions maybe provided by adding or removing torch components, e.g., inserting orremoving the gas control valve. Further, the various quick disconnectsemployed within the modular plasma arc torch 20 are capable ofconducting both gas and electric power, and are relatively compact so asto not interfere with operation of the plasma arc torch 12.

[0066] The description of the invention is merely exemplary in natureand, thus, variations that do not depart from the substance of theinvention are intended to be within the scope of the invention. Suchvariations are not to be regarded as a departure from the spirit andscope of the invention.

What is claimed is:
 1. A modular plasma arc torch comprising: a torchhead; a torch lead; and a quick disconnect operatively engaged betweenthe torch head and the torch lead, wherein the torch head is removablyconnected to the torch lead through the quick disconnect such that thetorch head and the torch lead may be quickly assembled and disassembled.2. The modular plasma arc torch according to claim 1, wherein the quickdisconnect comprises: a pin fitting; and a socket adapter, wherein thepin fitting is engaged within the socket adapter such that gas andelectric power are conducted through the quick disconnect.
 3. Themodular plasma arc torch according to claim 2, wherein: the pin fittingfurther comprises a plurality of resilient fingers defining a proximalend and a plurality of contact flanges disposed at the proximal end ofthe resilient fingers; and the socket adapter further comprises a sockethousing and a socket fitting disposed within the socket housing, whereinthe contact flanges engage the socket fitting to provide electricalcontact for supply of the electric power.
 4. The modular plasma arctorch according to claim 3, wherein the socket housing further comprisesa tapered internal shoulder that causes the resilient fingers to deflectradially inward for engagement of the contact flanges with the socketfitting.
 5. The modular plasma arc torch according to claim 4, whereinthe socket housing further comprises radial bores disposed adjacent thetapered internal shoulder that cause the socket housing to fractureshould an object other than the pin fitting be inadvertently forced intothe socket adapter.
 6. The modular plasma arc torch according to claim3, wherein the socket fitting defines a distal internal bore such thatthe contact flanges engage the distal internal bore for the electricalcontact.
 7. The modular plasma arc torch according to claim 6 furthercomprising a sleeve disposed within the distal internal bore to limitengagement of the contact flanges with the distal internal bore and tofacilitate disengagement of the pin fitting from the socket adapter. 8.The modular plasma arc torch according to claim 3 further comprising aplug disposed on a shoulder formed within the socket fitting, whereinthe plug inhibits electrical contact of an object inadvertently insertedwithin the socket adapter with the socket fitting.
 9. The modular plasmaarc torch according to claim 3 further comprising a snap ring disposedaround the socket fitting to secure the socket fitting within the sockethousing.
 10. The modular plasma arc torch according to claim 3 furthercomprising at least one o-ring disposed between the socket housing andthe socket fitting to seal a supply of gas.
 11. The modular plasma arctorch according to claim 3 further comprising at least one o-ringdisposed between the pin fitting and the socket housing to seal a supplyof gas.
 12. The modular plasma arc torch according to claim 2, whereinthe socket housing further comprises a threaded extension and the torchhead further comprises a threaded member, such that when the pin fittingis fully engaged within the socket adapter, the threaded extensionthreadably engages the threaded member to further secure the torch headto the torch lead.
 13. The modular plasma arc torch according to claim 2further comprising a torch handle defining positioning ribs, wherein thepositioning ribs further secure the torch head to the torch lead. 14.The modular plasma arc torch according to claim 2, wherein the pinfitting defines an internal bore and the socket fitting defines a distalinternal bore and a proximal internal bore, wherein the pin fittinginternal bore, the distal internal bore, and the proximal internal boreare in fluid communication to conduct the gas through the quickdisconnect.
 15. A modular plasma arc torch comprising: a torch head; agas control device; a first quick disconnect operatively engaged betweenthe torch head and the gas control device; a torch lead; and a secondquick disconnect operatively engaged between the gas control device andthe torch lead, wherein the torch head is removably connected to the gascontrol device through the first quick disconnect and the gas controldevice is removably connected to the torch lead through the second quickdisconnect such that the torch head, the gas control device, and thetorch lead may be quickly assembled and disassembled.
 16. The modularplasma arc torch according to claim 15, wherein: the first quickdisconnect comprises: a first pin fitting; and a first socket adapter;and the second quick disconnect comprises: a second pin fitting; and asecond socket adapter, wherein the first pin fitting is engaged withinthe first socket adapter, and the second pin fitting is engaged withinthe second socket adapter, such that gas and electric power areconducted through the first quick disconnect and the second quickdisconnect.
 17. The modular plasma arc torch according to claim 16,wherein: the first pin fitting and the second pin fitting furthercomprise a plurality of resilient fingers defining a proximal end and aplurality of contact flanges disposed at the proximal end of theresilient fingers; the first socket adapter further comprises a firstsocket housing and a first socket fitting disposed within the firstsocket housing; and the second socket adapter further comprises a secondsocket housing and a second socket fitting disposed within the secondsocket housing, wherein the contact flanges engage the socket fittingsto provide electrical contact for supply of the electric power.
 18. Themodular plasma arc torch according to claim 17, wherein the first andsecond socket housings further comprise a tapered internal shoulder thatcauses the resilient fingers to deflect radially inward for engagementof the contact flanges with the socket fittings.
 19. The modular plasmaarc torch according to claim 18, wherein the socket housings furthercomprise radial bores disposed adjacent the tapered internal shouldersthat cause the socket housings to fracture should objects other than thepin fittings be inadvertently forced into the socket adapters.
 20. Themodular plasma arc torch according to claim 17, wherein the first andsecond socket fittings define distal internal bores such that thecontact flanges engage the distal internal bores for the electricalcontact.
 21. The modular plasma arc torch according to claim 20 furthercomprising first and second sleeves disposed within the distal internalbores to limit engagement of the contact flanges with the distalinternal bores and to facilitate disengagement of the pin fittings fromthe socket adapters.
 22. The modular plasma arc torch according to claim17 further comprising a first plug disposed on a shoulder formed withinthe first socket fitting, and a second plug disposed on a shoulderformed within the second socket fitting, wherein the plug inhibitselectrical contact of objects inadvertently inserted within the socketadapters with the socket fittings.
 23. The modular plasma arc torchaccording to claim 17 further comprising snap rings disposed around thesocket fittings to secure the socket fittings within the sockethousings.
 24. The modular plasma arc torch according to claim 17 furthercomprising: a first o-ring disposed between the first socket housing andthe first socket fitting; and a second o-ring disposed between thesecond socket housing and the second socket fitting, wherein the o-ringsprovide gas-sealed interfaces between the socket housings and the socketfittings.
 25. The modular plasma arc torch according to claim 17 furthercomprising: a first pin fitting o-ring disposed between the first pinfitting and the first socket housing; and a second pin fitting o-ringdisposed between the second pin fitting and the second socket housing,wherein the o-rings provide gas-sealed interfaces between the pinfittings and the socket housings.
 26. The modular plasma arc torchaccording to claim 17, wherein: the first socket housing furthercomprises a first threaded extension; the second socket housing furthercomprises a second threaded extension; the torch head further comprisesa first threaded member, such that when the first pin fitting is fullyengaged within the first socket adapter, the first threaded extensionthreadably engages the first threaded member to further secure the torchhead to the gas control device; and the gas control device furthercomprises a second threaded member, such that when the second pinfitting is fully engaged within the second socket adapter, the secondthreaded extension threadably engages the second threaded member tofurther secure the gas control device to the torch lead.
 27. The modularplasma arc torch according to claim 17 further comprising a torch handledefining positioning ribs, wherein the positioning ribs further securethe torch head to the gas control device and the gas control device tothe torch lead.
 28. The modular plasma arc torch according to claim 17,wherein: the first and second pin fittings define an internal bore andthe first and second socket fittings define a distal internal bore and aproximal internal bore, wherein the first pin fitting internal bore isin fluid communication with the socket fitting internal bores, and thesecond pin fitting internal bore is in fluid communication with thesecond socket fitting internal bores to conduct the gas through thequick disconnects.
 29. A plasma arc torch head for producing plasmawithin a plasma arc torch comprising: a quick disconnect member disposedwithin a proximal end of the torch head, wherein the quick disconnectmember conducts gas and electric power through the plasma arc torch andis operable within a quick disconnect for quickly assembling the plasmaarc torch head to and disassembling the plasma arc torch head from atorch component within the plasma arc torch.
 30. The plasma arc torchhead according to claim 29, wherein the quick disconnect member is a pinfitting comprising a plurality of resilient fingers defining contactflanges to provide electrical contact for supply of the electric power.31. The plasma arc torch head according to claim 30, wherein the pinfitting further comprises an internal bore to conduct the gas.
 32. Theplasma arc torch head according to claim 30 further comprising athreaded member disposed adjacent the pin fitting, wherein the threadedmember is operable to further secure the plasma arc torch head to thetorch component within the plasma arc torch.
 33. The plasma arc torchhead according to claim 30, wherein the quick disconnect member is asocket adapter comprising a socket housing and a socket fitting disposedwithin the socket housing, wherein the gas and electric power areconducted through the socket fitting, and the socket housing insulatesthe socket adapter from a surrounding environment.
 34. The plasma arctorch head according to claim 33, wherein the socket housing furthercomprises a threaded extension that is operable to further secure theplasma arc torch head to the torch component within the plasma arctorch.
 35. A plasma arc torch head for producing plasma within a plasmaarc torch comprising: a quick disconnect member disposed within a distalend of the torch head, wherein the quick disconnect member conducts gasand electric power through the plasma arc torch and is operable within aquick disconnect for quickly assembling the plasma arc torch head to anddisassembling the plasma arc torch head from a component within theplasma arc torch.
 36. A plasma arc torch head for producing plasmawithin a plasma arc torch comprising: a quick disconnect member disposedwithin a proximal end of the torch head; and a quick disconnect memberdisposed within a distal end of the torch head, wherein the quickdisconnect members conduct gas and electric power through the plasma arctorch and are operable within a quick disconnect for quickly assemblingthe plasma arc torch head to and disassembling the plasma arc torch headfrom components within the plasma arc torch.
 37. A plasma arc torch leadfor delivering gas and electric power to a plasma arc torch comprising:a quick disconnect member disposed within a distal end of the torchlead, wherein the quick disconnect member conducts gas and electricpower through the plasma arc torch and is operable within a quickdisconnect for quickly assembling the torch lead to and disassemblingthe torch lead from a torch component within the plasma arc torch. 38.The plasma arc torch lead according to claim 37, wherein the quickdisconnect member is a pin fitting comprising a plurality of resilientfingers defining contact flanges to provide electrical contact forsupply of the electric power.
 39. The plasma arc torch lead according toclaim 38, wherein the pin fitting further comprises an internal bore toconduct the gas.
 40. The plasma arc torch lead according to claim 38further comprising a threaded member disposed adjacent the pin fitting,wherein the threaded member is operable to further secure the torch leadto the torch component within the plasma arc torch.
 41. The plasma arctorch lead according to claim 37, wherein the quick disconnect member isa socket adapter comprising a socket housing and a socket fittingdisposed within the socket housing, wherein the gas and electric powerare conducted through the socket fitting, and the socket housinginsulates the socket adapter from a surrounding environment.
 42. Theplasma arc torch lead according to claim 41, wherein the socket housingfurther comprises a threaded extension that is operable to secure thetorch lead to the torch component within the plasma arc torch.
 43. Aplasma arc torch lead for delivering gas and electric power to a plasmaarc torch comprising: a quick disconnect member disposed within aproximal end of the torch lead, wherein the quick disconnect memberconducts gas and electric power through the plasma arc torch and isoperable within a quick disconnect for quickly assembling the torch leadto and disassembling the torch lead from a component within the plasmaarc torch.
 44. A plasma arc torch lead for delivering gas and electricpower to a plasma arc torch comprising: a quick disconnect memberdisposed within a distal end of the torch lead; and a quick disconnectmember disposed within a proximal end of the torch lead, wherein thequick disconnect members conduct gas and electric power through theplasma arc torch and are operable within a quick disconnect for quicklyassembling the torch lead to and disassembling the torch lead fromcomponents within the plasma arc torch.
 45. A gas control device forcontrolling gas flow to a plasma arc torch comprising: a first quickdisconnect member disposed within a distal end of the gas controldevice; and a second quick disconnect member disposed within a proximalend of the gas control device, wherein the first quick disconnect memberand the second quick disconnect member conduct gas and electric powerthrough the plasma arc torch and are operable within a quick disconnectfor quickly assembling the gas control device to and disassembling thegas control device from torch components within the plasma arc torch.46. The gas control device according to claim 45, wherein: the firstquick disconnect member is a pin fitting comprising a plurality ofresilient fingers defining contact flanges to provide electrical contactfor supply of the electric power; and the second quick disconnect memberis a socket adapter comprising a socket housing and a socket fittingdisposed within the socket housing, wherein the gas and electric powerare conducted through the socket fitting, and the socket housinginsulates the socket adapter from a surrounding environment.
 47. The gascontrol device according to claim 46 further comprising a threadedmember disposed adjacent the pin fitting, wherein the threaded member isoperable to further secure the gas control device to one of the torchcomponents within the plasma arc torch.
 48. The gas control deviceaccording to claim 46, wherein the socket housing further comprises athreaded extension that is operable to further secure the gas controldevice to one of the torch components within the plasma arc torch. 49.The gas control device according to claim 45, wherein: the first quickdisconnect member is a socket adapter comprising a socket housing and asocket fitting disposed within the socket housing, wherein the gas andelectric power are conducted through the socket fitting, and the sockethousing insulates the socket adapter from a surrounding environment; andthe second quick disconnect member is a pin fitting comprising aplurality of resilient fingers defining contact flanges to provideelectrical contact for supply of the electric power.
 50. The gas controldevice according to claim 49 further comprising a threaded memberdisposed adjacent the pin fitting, wherein the threaded member isoperable to further secure the gas control device to one of the torchcomponents within the plasma arc torch.
 51. The gas control deviceaccording to claim 46, wherein the socket housing further comprises athreaded extension that is operable to further secure the gas controldevice to one of the torch components within the plasma arc torch.
 52. Agas control device for controlling gas flow to a plasma arc torchcomprising: a quick disconnect member disposed within a distal end ofthe gas control device, wherein the quick disconnect member conducts gasand electric power through the plasma arc torch and is operable within aquick disconnect for quickly assembling the gas control device to anddisassembling the gas control device from a component within the plasmaarc torch.
 53. A gas control device for controlling gas flow to a plasmaarc torch comprising: a quick disconnect member disposed within aproximal end of the gas control device, wherein the quick disconnectmember conducts gas and electric power through the plasma arc torch andis operable within a quick disconnect for quickly assembling the gascontrol device to and disassembling the gas control device from acomponent within the plasma arc torch.
 54. A quick disconnect foroperable engagement of components that conduct gas and electric powercomprising: a pin fitting; and a socket adapter, wherein the pin fittingis engaged within the socket adapter such that gas and electric powerare conducted through the quick disconnect.
 55. The quick disconnectaccording to claim 54, wherein: the pin fitting further comprises aplurality of resilient fingers defining a proximal end and a pluralityof contact flanges disposed at the proximal end of the resilientfingers; and the socket adapter further comprises a socket housing and asocket fitting disposed within the socket housing, wherein the contactflanges engage the socket fitting to provide electrical contact forsupply of the electric power.
 56. The quick disconnect according toclaim 55, wherein the socket housing further comprises a taperedinternal shoulder that causes the resilient fingers to deflect radiallyinward for engagement of the contact flanges with the socket fitting.57. The quick disconnect according to claim 56, wherein the sockethousing further comprises radial bores disposed adjacent the taperedinternal shoulder that cause the socket housing to fracture should anobject other than the pin fitting be inadvertently forced into thesocket adapter.
 58. The quick disconnect according to claim 55, whereinthe socket fitting defines a distal internal bore such that the contactflanges engage the distal internal bore for the electrical contact. 59.The quick disconnect according to claim 58, wherein the socket adapterfurther comprises a sleeve disposed within the distal internal bore tolimit engagement of the contact flanges with the distal internal boreand to facilitate disengagement of the pin fitting from the socketadapter.
 60. The quick disconnect according to claim 55 furthercomprising a plug disposed on a shoulder formed within the socketfitting, wherein the plug inhibits electrical contact of an objectinadvertently inserted within the socket adapter with the socketfitting.
 61. The quick disconnect according to claim 55 furthercomprising an o-ring disposed between the socket housing and the socketfitting to seal the gas.
 62. The quick disconnect according to claim 55further comprising an o-ring disposed between the pin fitting and thesocket housing to seal the gas.
 63. The quick disconnect according toclaim 55, wherein the socket housing further comprises a threadedextension and the quick disconnect further comprises a threaded member,such that when the pin fitting is fully engaged within the socketadapter, the threaded extension threadably engages the threaded memberto further the components.
 64. The quick disconnect according to claim55 further comprising a snap ring disposed around the socket fitting tosecure the socket fitting within the socket housing.
 65. The quickdisconnect according to claim 55, wherein the pin fitting defines aninternal bore and the socket fitting defines a distal internal bore anda proximal internal bore, wherein the pin fitting internal bore, thedistal internal bore, and the proximal internal bore are in fluidcommunication to conduct the gas through the quick disconnect.
 66. Aquick disconnect for use in connecting torch components within a plasmaarc torch comprising: a pin fitting comprising a plurality of resilientfingers defining a proximal end; a plurality of contact flanges disposedat the proximal end of the resilient fingers; and a socket adaptercomprising: a socket housing; a socket fitting disposed within thesocket housing, the socket fitting defining a proximal internal bore anda distal internal bore; a sleeve disposed within the distal bore of thesocket fitting; a plug disposed between the proximal internal bore andthe distal internal bore of the socket fitting; and a snap ring disposedaround the socket fitting, the snap ring securing the socket fitting tothe socket housing wherein the contact flanges engage the distalinternal bore of the socket fitting such that gas and electric power areconducted through the quick disconnect, the sleeve limits engagement ofthe contact flanges within the distal internal bore and facilitatesdisengagement of the pin fitting from the socket adapter, the pluginhibits electrical contact of an object inadvertently inserted withinthe socket adapter with the socket fitting, and the torch components maybe quickly assembled and disassembled.
 67. A quick disconnect memberoperable within a quick disconnect for operable engagement of componentsthat conduct gas and electric power comprising: a pin fitting comprisinga plurality of resilient fingers defining contact flanges to provideelectrical contact for supply of the electric power and a distalinternal bore for supply of the gas, wherein the pin fitting engages anadjacent quick disconnect member such that the components may be quicklyassembled and disassembled.
 68. The quick disconnect member according toclaim 67 further comprising a threaded member disposed adjacent the pinfitting, wherein the threaded member is operable to further secure thecomponents.
 69. A quick disconnect member operable within a quickdisconnect for operable engagement of components that conduct gas andelectric power comprising: a socket adapter comprising a socket housingand a socket fitting disposed within the socket housing, wherein the gasand electric power are conducted through the socket fitting, and thesocket housing insulates the socket adapter from a surroundingenvironment.
 70. The quick disconnect member according to claim 69,wherein the socket adapter further comprises a sleeve disposed withinthe socket fitting to limit engagement of and to facilitate removal ofan adjacent quick disconnect member.
 71. The quick disconnect memberaccording to claim 69, wherein the socket housing further comprises athreaded extension that is operable to further secure the components.72. A quick disconnect member operable within a quick disconnect foroperable engagement of components that conduct gas and electric powercomprising: a socket housing defining a tapered internal shoulder andradial bores disposed adjacent the tapered internal shoulder, whereinthe tapered internal shoulder facilitates insertion of an adjacent quickdisconnect member and the radial bores cause the socket housing tofracture should an object other than the quick disconnect member beinadvertently forced into the socket housing.
 73. The quick disconnectmember according to claim 72, wherein the socket housing furthercomprises a threaded extension to secure the socket housing to theadjacent quick disconnect member.
 74. A quick disconnect member operablewithin a quick disconnect for operable engagement of components thatconduct gas and electric power comprising: a socket fitting defining adistal internal bore and a proximal internal bore, wherein the internalbores conduct a supply of gas and the distal internal bore provideselectrical contact for an adjacent quick disconnect member such that thesocket fitting conducts electric power.
 75. A modular plasma arc torchcomprising: a plurality of torch components; and a plurality of quickdisconnects operatively engaged between the torch components, whereinthe torch components are removably connected through the quickdisconnects such that the torch components may be quickly assembled anddisassembled.
 76. The modular plasma arc torch according to claim 75,wherein at least one quick disconnect comprises: a pin fitting; and asocket adapter, wherein the pin fitting is engaged within the socketadapter such that gas and electric power are conducted through the quickdisconnect.
 77. The modular plasma arc torch according to claim 76,wherein the pin fitting defines a plurality of resilient fingers thatengage the socket adapter.
 78. The modular plasma arc torch according toclaim 76, wherein the socket adapter defines a plurality of fingersdefining undercuts, wherein the pin fitting is engaged within the socketadapter.
 79. The modular plasma arc torch according to claim 71, whereinat least one quick disconnect comprises a dual pitch locking connector.80. The modular plasma arc torch according to claim 75, wherein at leastone quick disconnect comprises: a socket member; a pin member disposedwithin the socket member; and a locking ring that secures the pin memberto the socket member.
 81. The modular plasma arc torch according toclaim 80 further comprising: a socket housing disposed around the socketmember; and a pin housing disposed around the pin member, wherein thelocking ring secures the pin housing to the socket housing.
 82. Themodular plasma arc torch according to claim 75, wherein at least onequick disconnect comprises: a socket; a canted coil spring disposedwithin the socket; and a pin, wherein the pin is slidably disposedwithin the socket and the canted coil spring secures the pin within thesocket.
 83. The modular plasma arc torch according to claim 75, whereinat least one torch component comprises a torch head.
 84. The modularplasma arc torch according to claim 75, wherein at least one torchcomponent comprises an anode, insulator body, and cathode assembly. 85.The modular plasma arc torch according to claim 75, wherein at least onetorch component comprises a gas flow control component.
 86. The modularplasma arc torch according to claim 75, wherein at least one torchcomponent comprises a torch lead.
 87. The modular plasma arc torchaccording to claim 75, wherein at least one torch component comprises atleast one electrical component.
 88. The modular plasma arc torchaccording to claim 87, wherein the electrical component is a powerswitch.
 89. The modular plasma arc torch according to claim 87, whereinthe electrical component is an electrical circuit that controls a supplyof electric power to the modular plasma arc torch.
 90. The modularplasma arc torch according to claim 75, wherein at least one torchcomponent is a plurality of signal and power pins.
 91. The modularplasma arc torch according to claim 90, wherein at least one torchcomponent is a conductive member engaged with the plurality of signaland power pins.
 92. The modular plasma arc torch according to claim 75,wherein at least one torch component comprises an adapter that connectsa torch lead to a power supply.
 93. The modular plasma arc torchaccording to claim 75, wherein at least one torch component comprises anadapter provides a connection for a torch head to a torch handle.
 94. Amodular plasma arc torch handle comprising: a first handle half; asecond handle half; at least one flexible tab disposed on the firsthandle half; and at least one receptacle disposed on the second handlehalf, wherein the flexible tab engages the receptacle to secure thefirst handle half to the second handle half.
 95. The modular plasma arctorch according to claim 94 further comprising at least one positioningpin disposed on the first handle half and at least one positioning holedisposed on the second handle half, wherein the positioning pin isdisposed within the positioning hole to position the first handle halfrelative to the second handle half.
 96. The modular plasma arc torchaccording to claim 95 further comprising: two flexible tabs disposedalong an upper periphery of the first handle half; two receptaclesdisposed along an upper periphery of the second handle half; twopositioning pins disposed along a lower periphery of the first handlehalf; and two positioning holes disposed along a lower periphery of thesecond handle half.
 97. A modular plasma arc torch comprising: a torchhead; a torch lead; and a quick disconnect operatively engaged betweenthe torch head and the torch lead, the quick disconnect comprising: apin fitting comprising a plurality of resilient fingers defining aproximal end and a plurality of contact flanges disposed at the proximalend of the resilient fingers; and a socket adapter comprising a sockethousing, a socket fitting disposed within the socket housing, and asleeve disposed within the socket fitting, the sleeve limitingengagement of the contact flanges with the socket fitting andfacilitating disengagement of the pin fitting from the socket adapter,wherein the resilient fingers are engaged within the socket fitting suchthat gas and electric power are conducted through the quick disconnect,and the torch head is removably connected to the torch lead through thequick disconnect such that the torch head and the torch lead may bequickly assembled and disassembled.
 98. A modular plasma arc torchcomprising: a torch head; a torch lead; a gas control device; a firstquick disconnect operatively engaged between the torch head and the gascontrol device; and a second quick disconnect operatively engagedbetween the gas control device and the torch lead, the quick disconnectscomprising: a pin fitting comprising a plurality of resilient fingersdefining a proximal end and a plurality of contact flanges disposed atthe proximal end of the resilient fingers; and a socket adaptercomprising a socket housing, a socket fitting disposed within the sockethousing, and a sleeve disposed within the socket fitting, the sleevelimiting engagement of the contact flanges with the socket fitting andfacilitating disengagement of the pin fitting from the socket adapter,wherein the resilient fingers are engaged within the socket fitting suchthat gas and electric power are conducted through the quick disconnect,the torch head is removably connected to the gas control device throughthe first quick disconnect, and the gas control device is removablyconnected to the torch lead through the second quick disconnect suchthat the plasma arc torch may be quickly assembled and disassembled. 99.A method of assembling a plasma arc torch, the method comprising thestep of: placing a quick disconnect member disposed within a distal endof a torch lead in engagement with a corresponding quick disconnectmember disposed within a proximal end of a torch head, wherein the torchhead and the torch lead are quickly assembled.
 100. The method accordingto claim 99 further comprising the step of: engaging a threaded memberdisposed on one of the quick disconnect members with a threadedextension on the corresponding quick disconnect member, wherein thetorch head is secured to the torch lead.
 101. A method of assembling aplasma arc torch, the method comprising the steps of: placing a quickdisconnect member disposed within a distal end of a torch lead inengagement with a corresponding quick disconnect member disposed withina proximal end of a gas control device; and placing a quick disconnectmember disposed within a distal end of a gas control device inengagement with a corresponding quick disconnect member disposed withina proximal end of a torch head, wherein the torch head, the torch lead,and the gas control device are quickly assembled.
 102. The methodaccording to claim 101 further comprising the step of: engaging threadedmembers disposed on the quick disconnect members with threadedextensions on the corresponding quick disconnect members, wherein thetorch head is further secured to the gas control device and the gascontrol device is further secured to the torch lead.
 103. A method ofdisassembling a plasma arc torch, the method comprising the step of:disengaging a quick disconnect member disposed within a distal end of atorch lead from engagement with a corresponding quick disconnect memberdisposed within a proximal end of a torch head, wherein the torch headand the torch lead are quickly disassembled.
 104. The method accordingto claim 103 further comprising the step of: disengaging a threadedmember disposed on one of the quick disconnect members with a threadedextension on the corresponding quick disconnect member prior todisengaging the disconnect member disposed within the distal end of thetorch lead from engagement with the corresponding quick disconnectmember disposed within the proximal end of the torch head, wherein thetorch head and the torch lead are quickly disassembled.
 105. A method ofdisassembling a plasma arc torch, the method comprising the steps of:disengaging a quick disconnect member disposed within a distal end of atorch lead from engagement with a corresponding quick disconnect memberdisposed within a proximal end of a gas control device; and disengaginga quick disconnect member disposed within a distal end of a gas controldevice from engagement with a corresponding quick disconnect memberdisposed within a proximal end of a torch head, wherein the torch head,the torch lead, and the gas control device are quickly disassembled.106. The method according to claim 105 further comprising the step of:disengaging threaded members disposed on the quick disconnect membersfrom threaded extensions on the corresponding quick disconnect members,wherein the torch head is unsecured from the gas control device and thegas control device is unsecured from the torch lead.
 107. A method ofassembling a plasma arc torch, the method comprising the step of:placing a quick disconnect member disposed within a torch component inengagement with a corresponding quick disconnect member disposed withinan adjacent torch component, wherein the torch components are quicklyassembled.
 108. A method of disassembling a plasma arc torch, the methodcomprising the step of: disengaging a quick disconnect member disposedwithin a torch component from engagement with a corresponding quickdisconnect member disposed within an adjacent torch component, whereinthe torch components are quickly disassembled.